RM38T0EC _58 Vehicle Interior _104612 HEATING / AIR CONDITIONING _0602275 COMPRESSOR(for HEV Model) A

HEATING / AIR CONDITIONING COMPRESSOR(for HEV Model) INSTALLATION

CAUTION / NOTICE / HINT

COMPONENTS (INSTALLATION)

2.365,3.271 3.115,3.438 0.75,0.167 0.646,0.177 1.729,0.344 1.083,0.167 2.01,5.542 3.01,5.708 1,0.167 0.198,2.229 1.281,2.396 1.083,0.167 2.469,2.656 3.219,2.823 0.75,0.167 3.469,1.604 4.552,1.771 1.083,0.167 2.083,1.5 7,3.5 4.917,2 5.042,3.25 5.792,3.417 0.75,0.167 6.844,0.24 6.51,0.24 false 4.635,5.094 4.635,5.427 false 6.677,3.781 6.344,3.781 false 4.354,2.385 4.208,2.385 false 2.969,0.615 2.677,0.615 false 0.979,0.875 0.604,0.875 false 2.344,0.802 2.073,0.708 2.073,0.708 1.906,0.708 false 2.073,0.26 1.74,0.26 false 3.354,5.625 3.021,5.625 false 2.458,2.74 2.292,2.74 2.292,2.74 2.292,2.573 false 3.458,1.688 3.292,1.688 3.292,1.688 2.708,2.521 false 0.688,1.833 0.688,2.219 false 2.719,3.063 2.719,3.26 false 5,1.5 5,3.5 false 1.677,1.885 1.677,2.271 false 6.021,2.281 5.688,2.281 false 5.365,3.042 5.365,3.24 false 5.531,0.083 6.479,0.552 0.948,0.469 18 false 1, 8 - 10 6.75,3.625 7.021,4.052 0.271,0.427 18 false 7 4.594,5.458 5.208,5.823 0.615,0.365 18 false 6 3.271,0.469 3.885,0.833 0.615,0.365 18 false 5 0.396,0.74 1.01,1.104 0.615,0.365 18 false 4 4.646,2.25 5.26,2.615 0.615,0.365 18 false 2 1.771,0.615 1.927,0.813 0.156,0.198 10 false ● 1.635,2.25 1.792,2.448 0.156,0.198 10 false ● 2.875,2.375 3.188,2.573 0.313,0.198 10 false x2 3.458,5.552 3.781,5.75 0.323,0.198 10 false x4 5.615,5.427 5.938,5.625 0.323,0.198 10 false x10 2.427,3.281 3.896,3.438 1.469,0.156 8 false 25 (255, 18) 0.271,2.24 2.844,2.396 2.573,0.156 8 false 9.8 (100, 87 in.*lbf) 2.073,5.542 4.521,5.698 2.448,0.156 8 false 7.5 (76, 66 in.*lbf) 0.708,0.177 3.281,0.333 2.573,0.156 8 false 9.8 (100, 87 in.*lbf) 3.094,3.031 3.406,3.229 0.313,0.198 10 false x2 2.354,2.375 2.667,2.573 0.313,0.198 10 false x2 2.542,2.667 4.021,2.885 1.479,0.219 8 false 25 (255, 18) 3.531,1.604 6.104,1.76 2.573,0.156 8 false 9.8 (100, 87 in.*lbf) 5.479,2.104 6.094,2.469 0.615,0.365 18 false 3 5.729,3.042 6.042,3.24 0.313,0.198 10 false x4 5.125,3.26 6.594,3.417 1.469,0.156 8 false 25 (255, 18)

Procedure		Part Name Code
1	ADJUST COMPRESSOR OIL	-	(202307,999999,_58,_104612,_0602275,RM100000002BK1E_01_0227,)	-	-
2	COMPRESSOR WITH MOTOR ASSEMBLY	88370	(202307,999999,_58,_104612,_0602275,RM100000002BK1E_01_0243,)	-	-
3	COMPRESSOR WITH MOTOR ASSEMBLY	88370	(202307,999999,_58,_104612,_0602275,RM100000002BK1E_01_0245,)	-	-
4	SUCTION HOSE SUB-ASSEMBLY	88704	(202307,999999,_58,_104612,_0602275,RM100000002BK1E_01_0211,)	-	-
5	DISCHARGE HOSE SUB-ASSEMBLY	88703	(202307,999999,_58,_104612,_0602275,RM100000002BK1E_01_0212,)	-	-
6	NO. 1 ENGINE UNDER COVER ASSEMBLY	51410	-	-	-
7	SERVICE PLUG GRIP	G3834	-	-	-
8	CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT	-	(202307,999999,_58,_104612,_0602275,RM100000002BK1E_01_0228,)	-	-
9	WARM UP COMPRESSOR	-	(202307,999999,_58,_104612,_0602275,RM100000002BK1E_01_0229,)	-	-
10	INSPECT FOR REFRIGERANT LEAK	-	(202307,999999,_58,_104612,_0602275,RM100000002BK1E_01_0230,)	-	-

*A	for FTMC Made	*B	for GTMC Made
	Nm (kgfcm, ft.*lbf): Specified torque	●	Non-reusable part
	Compressor oil ND-OIL 11 or equivalent	-	-

PROCEDURE

Hide Display 1.ADJUST COMPRESSOR OIL

When replacing the compressor with motor assembly with a new one:

2.094,0.198 2.375,0.552 0.281,0.354 18 false i

Gradually discharge the inert gas from the service valve, and drain the following amount of oil from the new compressor with motor assembly before installation.

Standard:: (Oil capacity inside the new compressor with motor assembly: 110 to 125 cc (3.73 to 4.22 fl. oz)) - (Remaining oil amount in the removed compressor with motor assembly) = (Oil amount to be removed from the new compressor)

NOTICE:: ·

If a new compressor with motor assembly is installed without removing some oil, there will be too much oil in the system due to the oil remaining in the pipes of the vehicle. Excessive oil in the system prevents heat exchange in the refrigeration cycle and causes ineffective cooling.

·

If the amount of oil remaining in the old compressor with motor assembly is too small, check the air conditioning system for oil leaks.

·

Be sure to use ND-OIL 11 or equivalent compressor oil. If any compressor oil other than ND-OIL 11 is used, compressor with motor assembly insulation performance may decrease, resulting in leakage of electric power.

Hide Display 88370 2.INSTALL COMPRESSOR WITH MOTOR ASSEMBLY (for FTMC Made)

5.208,2.479 5.552,2.271 true 5.583,2.146 5.771,2.365 0.188,0.219 10 false *c 4.781,3.469 4.99,3.688 0.208,0.219 10 true *a 5.417,4.406 5.625,4.625 0.208,0.219 10 true *b 0.156,2.042 1.823,2.396 1.667,0.354 18 false ii, iii 3.844,2.073 5.219,2.427 1.375,0.354 18 false iv, v 1.958,0.01 3.333,0.365 1.375,0.354 18 false i

*a	Connector (A)	*b	Connector (B)
*c	Green-colored Lock	-	-
	Slide	-	-

Using an E8 "TORX" socket wrench, install the compressor with motor assembly with the 2 stud bolts.

Torque:: 9.8 N*m (100 kgf*cm, 87 in.*lbf)

ii.

Install the 2 nuts.

Torque:: 25 N*m (255 kgf*cm, 18 ft.*lbf)

iii.

Install the 2 bolts.

Torque:: 25 N*m (255 kgf*cm, 18 ft.*lbf)

iv.

Connect the connector (B).

Remove the insulating tape from the connector (A), connect the connector (A) and slide the green-colored lock as shown in the illustration to securely lock it.

CAUTION:: Make sure to wear insulated gloves.

NOTICE:: Make sure that the connector is connected securely.

Hide Display 88370 3.INSTALL COMPRESSOR WITH MOTOR ASSEMBLY (for GTMC Made)

5.333,0.385 5.677,0.177 true 1.823,0.333 1.979,0.531 0.156,0.198 10 true 1 1.917,1.979 2.073,2.177 0.156,0.198 10 true 2 1.531,2.156 1.688,2.354 0.156,0.198 10 true 3 1.448,0.656 1.604,0.854 0.156,0.198 10 true 4 5.708,0.083 5.896,0.302 0.188,0.219 10 false *c 5.083,2.031 5.292,2.25 0.208,0.219 10 true *a 5.615,2.542 5.823,2.76 0.208,0.219 10 true *b 0.406,0.063 1.781,0.417 1.375,0.354 18 false i, ii 3.875,0.083 5.25,0.438 1.375,0.354 18 false iii, iv

*a	Connector (A)	*b	Connector (B)
*c	Green-colored Lock	-	-
	Slide	-	-

Temporarily install the compressor with motor assembly with the 4 bolts.

ii.

Tighten the 4 bolts to install the compressor with motor assembly in the order shown in the illustration.

Torque:: 25 N*m (255 kgf*cm, 18 ft.*lbf)

iii.

Connect the connector (B).

iv.

Remove the insulating tape from the connector (A), connect the connector (A) and slide the green-colored lock as shown in the illustration to securely lock it.

CAUTION:: Make sure to wear insulated gloves.

NOTICE:: Make sure that the connector is connected securely.

Hide Display 88704 4.CONNECT SUCTION HOSE SUB-ASSEMBLY

1.104,0.125 1.385,0.479 0.281,0.354 18 false i 4.49,0.135 4.771,0.49 0.281,0.354 18 false ii 2.646,1.958 2.906,2.25 0.26,0.292 18 true iii

Remove the vinyl tape from the suction hose sub-assembly and sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor with motor assembly.

Compressor Oil:: ND-OIL 11 or equivalent

ii.

Install the O-ring to the suction hose sub-assembly.

NOTICE:: Keep the O-ring and O-ring fitting surface free of foreign matter.

iii.

Connect the suction hose sub-assembly to the compressor with motor assembly with the bolt.

Torque:: 9.8 N*m (100 kgf*cm, 87 in.*lbf)

Hide Display 88703 5.CONNECT DISCHARGE HOSE SUB-ASSEMBLY

1.083,0.125 1.365,0.479 0.281,0.354 18 false i 4.49,0.135 4.771,0.49 0.281,0.354 18 false ii 2.063,1.969 2.344,2.323 0.281,0.354 18 false iii

Remove the vinyl tape from the discharge hose sub-assembly and sufficiently apply compressor oil to a new O-ring and the fitting surface of the compressor with motor assembly.

Compressor Oil:: ND-OIL 11 or equivalent

ii.

Install the O-ring to the discharge hose sub-assembly.

NOTICE:: Keep the O-ring and O-ring fitting surface free of foreign matter.

iii.

Connect the discharge hose sub-assembly to the compressor with motor assembly with the bolt.

Torque:: 9.8 N*m (100 kgf*cm, 87 in.*lbf)

Hide Display 51410 6.INSTALL NO. 1 ENGINE UNDER COVER ASSEMBLY

Hide Display G3834 7.INSTALL SERVICE PLUG GRIP

Click hereEngine / Hybrid System>HYBRID / BATTERY CONTROL>SERVICE PLUG GRIP>INSTALLATION202307,999999,_51,_144957,_0604242,RM100000002BTR8,

Hide Display 8.CHARGE AIR CONDITIONING SYSTEM WITH REFRIGERANT

Click hereVehicle Interior>HEATING / AIR CONDITIONING>REFRIGERANT>REPLACEMENT202307,999999,_58,_104612,_0500005,RM100000002BK0U_01_0002,

Hide Display 9.WARM UP COMPRESSOR

Click hereVehicle Interior>HEATING / AIR CONDITIONING>REFRIGERANT>REPLACEMENT202307,999999,_58,_104612,_0500005,RM100000002BK0U_01_0014,

Hide Display 10.INSPECT FOR REFRIGERANT LEAK

Click hereVehicle Interior>HEATING / AIR CONDITIONING>REFRIGERANT>REPLACEMENT202307,999999,_58,_104612,_0500005,RM100000002BK0U_01_0004,